Patch Assembly for Roof Decking and Method

ABSTRACT

A patch for patching a hole in roof decking includes a rigid plug body that has a peripheral edge and that is of a size receivable in the hole in a manner enabling the plug body to be positioned in edgewise juxtaposition with the roof decking. The patch also includes a plurality of separate clips separately secured to the plug body at spaced-apart locations adjacent the peripheral edge of the plug body. A portion, or ear, of each clip extends laterally and outwardly beyond the peripheral edge of the plug body so that it can be disposed on the roof decking and suspend the plug body within the hole. If desired, a flexible flashing material can be applied over the plug body and clips to form a fluid-tight seal between any gaps between the plug body and roof decking. A method of installing the patch is also provided.

BACKGROUND OF THE INVENTION

The present invention relates to patching holes in roof decking, and more particularly, the present invention relates to patching holes in roofs as a result of removing pre-existing roof pots, such as when converting to a ridge ventilation system.

It is useful, and in many locales a building code requirement, that certain interior areas of a building, such as an area underneath a roof, be provided with a means to permit air exchange. The ventilation prevents undue heat buildup that can render the living quarters of the building uncomfortable and that can impose unreasonable energy requirements for cooling. Proper ventilation also preserves the structural integrity of the building structure, such as the roof and roof coverings.

A roof pot vent provides localized ventilation through a roof deck via a relative small opening, such as a 6 inches by 6 inches or 8 inches by 8 inches opening cut in the roof deck. Typically, several such roof pot vents are spaced apart below the roof ridge of a building structure on a rearward sloping face of the roof so as not to be visible from a front of the building.

When re-roofing a pre-existing structure and/or replacing a roof covering, or when enhanced ventilation is desired, roof pot vents are typically removed from the roof and a ridge ventilation system is installed. A ridge vent is an elongate, low-profile vent that extends along substantially the full length of a roof ridge thereby permitting hot and/or humid air to rise up through an elongate open slot cut in the peak of the roof. Due to the length and location of the ridge vent, greater amounts of ventilation at increased flow rates are provided continuously and uniformly along substantially the full length of the roof ridge thereby providing superior ventilation relative to roof pot vents. In addition, cap shingles or like coverings are applied over the low profile ridge vents thereby providing an additional aesthetic advantage.

Examples of roof ridge vents are provided by U.S. Pat. No. 5,960,595 issued to McCorsley et al., U.S. Pat. Nos. 6,298,613 B1, 6,308,472 B1, 5,902,432 and 5,673,521 issued to Coulton et al., U.S. Pat. Nos. 6,277,024 B1 and 6,981,916 B2 issued to Coulton, and U.S. Pat. No. 4,942,699 issued to Spinelli and U.S. Patent Application Publication Nos. 2006/0079173 A1 and 2006/0154597 A1 of Coulton et al. and 2005/0136831 A1 and 2006/0040608 A1 of Coulton. Each of the above referenced patents and published applications are owned, or co-owned, by Benjamin Obdyke, Inc., the assignee of the present application.

A problem presented with the removal of a roof pot is that a generally rectangular or square hole remains in the roof decking after the roof pot is removed and discarded. A patch specifically provided for such holes is disclosed by U.S. Pat. No. 6,918,219 B1 of Olson. See also U.S. Pat. No. 6,797,354 B2 issued to Fleck, U.S. Pat. No. 4,782,642 issued to Conville, U.S. Pat. No. 5,269,861 issued to Gilbreath, U.S. Pat. No. 6,162,525 issued to Amy, and U.S. Pat. No. 5,839,241 issued to Cacossa et al. and U.S. Patent Application Publication No. 2004/0045245 A1 of O'Brien for patches in general.

While the patches disclosed in the above referenced patents and published application may function in an acceptable manner, there continues to be a need for alternatives with respect to the design, manufacture and installation of patches for holes in roof decking. A desired patch should be capable of proper installation in a manner requiring labor skills possessed by the average roofer, should prevent the formation of leaks, and should be capable of efficient manufacture from inexpensive materials.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a patch for patching a hole in roof decking. The patch includes a rigid plug body that has a peripheral edge and that is of a size receivable in the hole in a manner enabling the plug body to be positioned in edgewise juxtaposition with the roof decking. The patch also includes a plurality of separate clips separately secured to the plug body at spaced-apart locations adjacent the peripheral edge of the plug body. A portion of each clip extends laterally and outwardly beyond the peripheral edge of the plug body so that it can be disposed on the roof decking and suspend the plug body within the hole.

According to some contemplated embodiments of the present invention, the patch further includes a sheet of flashing material that is bonded to an upper surface of the plug body and that has an outermost peripheral section extending beyond the peripheral edge of the plug body encompassing the plug body. Preferably, the flashing material is a self-adhering, flexible or elastic material that can be used to form a fluid-tight seal between the juxtaposed edges of the plug body and roof decking.

Another aspect of the present invention relates to a patched roof assembly. The assembly includes roof decking that has a hole therein and a rigid plug body that has a peripheral edge and that is positioned in the hole such that the plug body is in edgewise juxtaposition with the roof decking. The assembly also includes a plurality of separate clips separately secured to the plug body at spaced apart locations adjacent the peripheral edge of the plug body. A portion of each clip extends laterally and outwardly beyond the peripheral edge of the plug body such that the clip portions are disposed on the roof decking and suspend the plug body within the hole. Headed fasteners or staples are used to secure the clips to the roof decking. Typically, the assembly will also include a layer of roofing underlayment, such as roofing felt or paper, applied over the plug body and roof decking and shingles or like exterior roof covering applied over the underlayment. According to some embodiments of the present invention, a sheet of self-adhering, flexible and/or elastic flashing material is applied over the plug and roof decking and under the roofing felt or paper to form a fluid tight seal between the juxtaposed edges of the plug body and roof decking.

A further aspect of the present invention is related to a method of converting a roof pot vented roof to a ridge ventilated roof. A pre-existing roof pot vent and surrounding shingles and underlayment are removed from roof decking thereby leaving a hole in the roof decking. A one-piece plug body is inserted into the hole such that the plug body is positioned in edgewise juxtaposition with the roof decking. The plug body has a plurality of separate clips separately secured to the plug body at spaced apart locations such that a portion of each clip extends laterally and outwardly from the plug body and onto the roof decking to thereby suspend the plug body in the hole. Headed fasteners or staples are applied to the clips to secure the clips to the roof decking. Thereafter, underlayment and shingles, or like exterior roof covering, are applied over the plug body and surrounding roof decking, and a ridge vent is installed on a ridge of the roof. The method can also include the step of forming a fluid tight seal between the juxtaposed edges of the plug body and roof decking with a sheet of self-adhering, flexible and/or elastic flashing material.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of the present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which:

FIG. 1 is an exploded view of the patch assembly according to the present invention;

FIG. 2 is a perspective view of a patch assembly according to the present invention; and

FIG. 3 is a cross-sectional view along line 3-3 of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

The lower part of FIG. 1 illustrates a roof deck 10 of a building, such as a house. Typically, the roof deck will be sloped and will extend to a ridge or peak (not shown). The roof deck includes decking 12, such as sheets of plywood, oriented strand board, or the like and an exterior covering 14, such as shingles. An underlayment, such as roofing paper or felt, is often installed over the decking 12 beneath the covering 14.

An opening 16 is provided in the decking 12, for instance, when a roof pot (not shown) or the like is removed from the roof. Upon removing the roof pot, the adjacent covering 14 and underlayment are also required to be removed. In the illustrated embodiment, the opening 16 is generally square; however, it could be any shape including, for instance, rectangular.

The present invention is directed to a patch 20 for fixing the hole in the roof decking 12. The patch 20 includes a relatively rigid plug body 22 made, for instance, of wood including plywood, oriented strand board, or the like or composite materials. The size and shape of the plug body 22 is provided such that it can be readily inserted into the opening 16 in edgewise juxtaposition with the surrounding decking 12. For example, see FIG. 3.

By way of example, and not by way of limitation, the opening 16 may be about 8 inches by 8 inches, which is typical of most roof pots. Alternatively, the installer may enlarge a smaller-sized or irregular-shaped hole in the decking 12 by cutting the decking 12 to form a generally square opening 16 having, for instance, eight inch sides. The plug body 22 can be formed of substantially the same type of material as the decking 12, such as plywood, and of substantially the same thickness. The plug body 22, for example, can have planar upper and lower faces, 24 and 26, and be square in plan with each of its four side edges 28 being about 7.75 inches in length. Accordingly, the size of the plug body 22 permits it to be easily dropped or inserted into the opening 16 with only relatively small-sized gaps being formed between the peripheral edges 28 of the plug body 22 and the edges of the surrounding decking 12. Preferably, the gaps are within a range of about 0 to 0.25 inch. Of course, larger gaps and openings and plug bodies of other shapes and dimensions can also be utilized according to the present invention.

A plurality of separate clips 30 are used to suspend the plug body 22 in the opening 16. As an example, the clips 30 can be those disclosed in U.S. Pat. No. 4,782,642 issued to Conville, the disclosure of which is incorporated herein by reference. Accordingly, the clips 30 are made of a relatively rigid material, such as metal or the like, and have upper and lower opposed prongs, 32 and 34, that receive and grip the peripheral edge 28 of the plug body 22. Alternatively, the clips can be made of plastic, fabric, or like materials. The patch 20 can include four equally spaced-apart clips 30, one on each peripheral edge 28 of the plug body 22. See FIG. 1. Alternatives include using only an opposed pair of clips 30 on the plug body 22 or using multiple clips 30 on each side edge 28. Preferably, the clips 30 are secured to the plug body 22 with one or more headed fasteners 36, such as screws or the like, or a staple or the like. Further, preferably the clips 30 are pre-assembled to the plug body 22 thereby enabling a roofer standing or kneeling on a sloped surface of a roof to merely drop or insert the pre-assembled patch 20 into the opening 16.

Each clip 30 includes a flange, or ear, 38 that extends laterally and outwardly of the peripheral edge 28 of the plug body 22 so that the ear 38 is in position to engage an upper surface of the roof decking 12 when the patch 20 is positioned in the opening 16 in edgewise juxtaposition with the decking 12. The ears 38 of the patch 20 suspend the plug body 22 in the opening 16 and prevent the patch 20 from falling completely through the opening 16. Accordingly, the clips 30 should be relatively rigid and of sufficient strength to support the patch 20 in the opening 16, even if a roofer should stand directly on the patch 20 after installation thereof.

After the patch 20 is inserted in the opening 16, headed fasteners 40, such as nails or screws, or staples or the like are applied to the ears 38 of the clips 30 to secure the clips 30 to the underlying roof decking 12. See FIG. 3. Thus, with the opening 16 now patched, roofing underlayment and an exterior covering 14, such as shingles, can be applied over the patch 20 to finish the roof 10.

If enhanced waterproofing is desired, the patch 20 can also include a relatively thin sheet of flashing material 42. As an example, the flashing material can be a self-adhering, flexible, elastic flashing material that includes an underside 44 with an adhesive backing 46. Accordingly, with the clips 30 installed on the plug body 22, the flashing material 42 can be bonded to the upper surface or face 24 of the plug body 22 directly over the upper prongs 32 of the clips 30 and over the headed fasteners 36 that secure the clips 30 to the plug body 22.

The flashing material 42 is of a size that is greater than the size of the plug body 22 such that an outer peripheral section 48 of the flashing material 42 extends beyond the peripheral edges 28 of the plug body 22 and the ears 38 of the clips 30. See FIG. 2. As an example, each ear 38 may extend about 1.625 inches beyond the peripheral edge 28 of the plug body 22, and the outer peripheral section 48 of the flashing material 42 may extend two or more inches from the peripheral edge 28 of the plug body 22. Preferably, the outer peripheral section 48 of the flashing material 42 is continuous and encompasses the plug body 22. Accordingly, a continuous fluid-tight seal can be formed between the flashing material 42 and the decking 12 and completely surround the opening 16. This reduces the likelihood of any liquid or gas flow through the decking 12 via any gaps between the plug body 22 and the decking 12.

The patch 20 can be provided pre-assembled with the flashing material 42 bonded to the plug body 22. Release sheets 50 can be secured to the exposed underside 44 of the flashing material 42 to cover the adhesive backing 46 on the outer peripheral section 48 of the flashing material 42. See FIG. 1. This permits the roofer to insert the patch 20 with attached flashing material 42 in the opening 16, and flex, bend, or fold the outer peripheral section 48 of the flashing material 42 away from one of the ears 38 of the clips 30 thereby enabling the headed fastener 40 or staple to be applied to the ear 38 without requiring the headed fastener 40 or staple to extend through the flashing material 42. Thereafter, the release sheet 50 can be removed to expose the adhesive backing 46, and the flashing material 42 can be pressed against the roof decking 12 thereby bonding the flashing material 42 to the roof decking 12 over the ear 38. This can be repeated adjacent each peripheral edge 28 of the plug body 22. See FIG. 2. Thus, the flashing material 42 is bonded to the upper surface 24 of the plug body 22 and the roof decking 12 surrounding the opening 16 and bridges across and seals any gaps therebetween. Thereafter, an underlayment and roof covering 14 can be applied over the flashing material 42.

The above-described patch, patched roof assembly, and method of applying the patch according to the present invention provide a unique patch that is easy to install, inexpensive to manufacture, and can provide a fluid tight seal. The method is particularly useful when converting a roof with roof pots to a ridge ventilation system. In this case, the roof pots are removed, the patch according to the present invention is installed as discussed above, underlayment and shingles or like covering are applied over the patch, and a ridge vent is installed on the ridge of the roof.

While preferred patches, assemblies, and methods have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the present invention as defined in the appended claims. 

1. A patch for patching a hole in roof decking, comprising: a rigid plug body having a peripheral edge and being of a size receivable in the hole in a manner enabling said plug body to be positioned in edgewise juxtaposition with the roof decking; and a plurality of separate clips separately secured to said plug body at spaced apart locations adjacent said peripheral edge, a portion of each clip extending laterally and outwardly beyond said peripheral edge for seating on the roof decking and suspending said plug body in the hole.
 2. A patch according to claim 1, wherein each of said separate clips is made of metal, plastic, or fabric.
 3. A patch according to claim 2, wherein said plug body is substantially rectangular in plan, has a substantially planar upper surface, and is made of wood or a composite material.
 4. A patch according to claim 3, wherein said peripheral edge includes four linear edges forming a square, and wherein said plurality of separate clips includes four separate clips with one of said separate clips being secured to each of said linear edges.
 5. A patch according to claim 4, and further comprising headed fasteners or staples that secure said clips to said plug body.
 6. A patch according to claim 1, further comprising a separate sheet of flashing material for forming a fluid-tight seal between said plug body and the roof decking, said flashing material having an underside bonded to an upper surface of said plug body and extending over said clips.
 7. A patch according to claim 6, wherein said flashing material includes a peripheral section that extends laterally beyond said peripheral edge of said plug body and said laterally-extending portions of said clips.
 8. A patch according to claim 7, wherein said peripheral section of said flashing material is continuous and encompasses said peripheral edge of said plug body.
 9. A patch according to claim 8, wherein said peripheral section of said flashing material is flexible such that it can be folded away from said laterally-extending portions of said clips to expose said laterally-extending portions of said clips thereby enabling said clips to be secured to the roof decking.
 10. A patch according to claim 9, wherein said underside of said flashing material has an adhesive backing that bonds said flashing material to said plug body, and further comprising at least one release sheet secured to said adhesive backing on said underside of said peripheral section of said flashing material.
 11. A patch according to claim 10, wherein said flashing material is a self-adhering, elastic, flexible flashing material.
 12. A patch according to claim 11, wherein said plug body is substantially square in plan and is made of solid wood or a composite material, wherein said plurality of clips includes at least four separate metal, plastic or fabric clips substantially equally spaced-apart about said peripheral edge of said plug body, and further comprising headed fasteners or staples that secure said clips to said plug body.
 13. A patched roof assembly, comprising: roof decking having a hole therein; a rigid plug body having a peripheral edge and being positioned in said hole such that said plug body is in edgewise juxtaposition with said roof decking; a plurality of separate clips separately secured to said plug body at spaced apart locations adjacent said peripheral edge, a portion of each clip extending laterally and outwardly beyond said peripheral edge of said plug body such that said clip portions seat on said roof decking and suspend said plug body in said hole; and a plurality of headed fasteners or staples securing said clips to said roof decking.
 14. A patched roof assembly according to claim 13, further comprising a layer of roofing felt or paper applied over said roof decking, plug, and clips and one or more shingles applied over said roofing felt or paper and secured to said roof decking and plug with headed fasteners or staples.
 15. A patched roof assembly according to claim 14, wherein said plurality of clips includes at least four separate clips, wherein each of said separate clips is made of metal, plastic or fabric and is secured to said plug body with headed fasteners or staples, wherein said hole and said plug body are each substantially rectangular in plan, and wherein said plug body has a substantially planar upper surface and is made of solid wood or composite material.
 16. A patched roof assembly according to claim 14, further comprising a separate sheet of flashing material having an underside bonded to an upper surface of said plug body and said roof decking surrounding said hole, said flashing material extending over said clips and said headed fasteners or staples and under said roofing felt or paper and forming a waterproof seal between said plug body and said roof decking.
 17. A patched roof assembly according to claim 16, wherein said flashing material has a peripheral section that extends laterally beyond said peripheral edge of said plug body and continuously about said peripheral edge to encompasses said peripheral edge of said plug body.
 18. A patched roof assembly according to claim 17, wherein said flashing material is a self-adhering, elastic, flexible flashing material.
 19. A patched roof assembly according to claim 18, wherein said plurality of clips includes at least four separate clips, wherein each of said separate clips is made of metal, plastic, or fabric and is secured to said plug body with headed fasteners or staples, wherein said hole and said plug body are each substantially square in plan, and wherein said plug body has a substantially planar upper surface and is made of solid wood or composite material.
 20. A method of converting a roof pot vented roof to a ridge ventilated roof, comprising the steps of: removing a pre-existing roof pot vent and shingles and underlayment adjacent the roof pot vent from roof decking thereby leaving a hole in the roof decking; inserting a plug body into the hole such that said plug body is positioned in edgewise juxtaposition with the roof decking, the plug body having a plurality of separate clips separately secured to said plug body at spaced apart locations such that a portion of each clip extends laterally and outwardly from the plug body and onto the roof decking to suspend the plug body in the hole; securing the clips to the roof decking with headed fasteners or staples; installing underlayment and shingles over the roof decking, plug body, and clips; and installing a ridge vent on a ridge of the roof.
 21. A method according to claim 20, wherein the plurality of clips include at least four separate clips, wherein each of the separate clips is made of metal, plastic, or fabric and is secured to the plug body with headed fasteners or staples, wherein the hole and plug body are each substantially rectangular in plan, and wherein the plug body has a substantially planar upper surface and is made of solid wood or composite material.
 22. A method according to claim 20, wherein a separate sheet of flashing material is bonded to an upper surface of the plug body and includes an outer peripheral section that extends outwardly of the plug body, that encompasses the plug body, and that extends laterally beyond and over said clips and, and wherein said step of securing the clips to the roof decking includes flexing the flashing material away from the laterally-extending portion of the clips such that the headed fasteners or staples securing the clips to the roof decking are not applied through the flashing material.
 23. A method according to claim 22, further comprising the step of, after said step of securing the clips to the roof decking and before said step of installing underlayment and shingles, bonding the outer peripheral section of the flashing material to the roof decking over the clips and headed fasteners or staples such that a continuous waterproof seal is formed between the juxtaposed plug body and roof decking.
 24. A method according to claim 23, wherein said step of bonding the outer peripheral section of the flashing material to the roof decking includes removing at least one release sheet covering an adhesive backing of the outer peripheral section. 